Method for the dehydration of 3-hydroxypropanoic acid to form acrylic acid

ABSTRACT

The invention relates to a process for dehydrating aqueous 3-hydroxypropionic acid to acrylic acid in the liquid phase, wherein aqueous acrylic acid is removed continuously from the liquid phase and the liquid phase comprises an inert organic solvent 1.

The invention relates to a process for dehydrating aqueous3-hydroxypropionic acid to acrylic acid in the liquid phase, whereinaqueous acrylic acid is removed continuously from the liquid phase andthe liquid phase comprises an inert organic solvent 1.

Because of its very reactive double bond and its carboxylic acid group,acrylic acid is a valuable monomer for preparation of polymers, forexample water-absorbing polymer particles, binders for water-basedemulsion paints, and adhesives dispersed in aqueous solvent.

Water-absorbing polymer particles are used to produce diapers, tampons,sanitary napkins and other hygiene articles, but also as water-retainingagents in market gardening. The water-absorbing polymer particles arealso referred to as superabsorbents.

The production of water-absorbing polymer particles is described in themonograph “Modern Superabsorbent Polymer Technology”, F. L. Buchholz andA. T. Graham, Wiley-VCH, 1998, pages 71 to 103.

On the industrial scale, acrylic acid is prepared almost exclusivelyfrom fossil raw materials. This is regarded as disadvantageous by theconsumers of the hygiene articles. There is therefore a need to producethe water-absorbing polymer particles used in the hygiene articles fromrenewable raw materials.

One possible route is the fermentative preparation of 3-hydroxypropionicacid and the conversion thereof to acrylic acid. The preparation of3-hydroxypropionic acid by fermentation is described, for example, in WO2012/074818 A2.

The dehydration of 3-hydroxypropionic acid in the gas phase is mentionedin U.S. Pat. No. 7,538,247.

The dehydration of 3-hydroxypropionic acid in the liquid phase ismentioned, for example, in WO 2006/092271 A2, WO 2008/023039 A1, JP2010-180171, EP 2 565 211 A1 and EP 2 565 212 A1.

It was an object of the present invention to provide an improved processfor preparing acrylic acid based on renewable raw materials.

The object was achieved by a process for continuously dehydratingaqueous 3-hydroxypropionic acid to aqueous acrylic acid in the liquidphase, the liquid phase having a temperature of 120 to 250° C., aqueous3-hydroxypropionic acid being continuously supplied to the liquid phaseand the aqueous acrylic acid being withdrawn continuously from theliquid phase, wherein the liquid phase comprises 5 to 95% by weight ofan inert organic solvent 1.

The liquid phase has a temperature of preferably 130 to 220° C., morepreferably of 140 to 200° C., most preferably of 150 to 180° C.

The inert organic solvent 1 has a solubility in water at 23° C. ofpreferably less than 5 g per 100 ml of water, more preferably less than1 g per 100 ml of water and most preferably of less than 0.2 g per 100ml of water.

The aqueous 3-hydroxypropionic acid used in the process according to theinvention comprises preferably at least 10% by weight, more preferablyat least 20% by weight and most preferably at least 30% by weight ofwater.

The liquid phase comprises preferably from 10 to 90% by weight, morepreferably from 20 to 80% by weight and most preferably from 30 to 60%by weight of the inert organic solvent 1.

The boiling point of the inert organic solvent 1 at 1013 mbar is in therange from preferably 200 to 350° C., more preferably from 250 to 320°C., most preferably from 280 to 300° C. Suitable inert organic solvents1 are, for example, phthalic esters such as dimethyl phthalate anddiethyl phthalate, isophthalic esters such as dimethyl isophthalate anddiethyl isophthalate, terephthalic esters such as dimethyl terephthalateand diethyl terephthalate, alkanoic acids such as nonanoic acid anddecanoic acid, biphenyl and/or diphenyl ether.

The aqueous acrylic acid formed in the dehydration is preferably removedby distillation. Rectification columns are particularly suitable forthis purpose. Through the selection of the separation plates and of thereflux ratio, the content of 3-hydroxypropionic acid in the distillatecan be kept low.

Advantageously, a sufficiently long residence time is established in theliquid phase, i.e. the space-time yield should not be too high.Excessively low space-time yields make the process unnecessarily costly.The space-time yield is preferably from 10 to 150 kg/h of acrylic acid,more preferably from 20 to 100 kg/h of acrylic acid, most preferably 30to 80 kg/h of acrylic acid, in each case per kg of liquid phase. Thespace-time yield is the quotient of acrylic acid removed per unit timeand the reactor volume.

The residence time in the liquid phase is preferably at least 10minutes, more preferably at least 30 minutes, most preferably at least60 minutes. The residence time is the quotient of the amount of liquidphase in the dehydration and the feed rate.

The ratio of oligomeric 3-hydroxypropionic acid to monomeric3-hydroxypropionic acid in the liquid phase is preferably at least 1:1,more preferably at least 3:1, most preferably 5:1.

Relatively low concentrations of monomeric 3-hydroxypropionic acid inthe liquid phase, i.e. relatively high ratios of oligomeric3-hydroxypropionic acid to monomeric 3-hydroxypropionic acid, facilitatethe distillative separation of acrylic acid and 3-hydroxypropionic acid.

The ratio of oligomeric 3-hydroxypropionic acid to monomeric3-hydroxypropionic acid in the aqueous 3-hydroxypropionic acid (feed) ispreferably at least 1:20, more preferably at least 1:15, more preferablyat least 1:10 and most preferably 1:5. Smaller concentrations ofmonomeric 3-hydroxypropionic acid in the aqueous 3-hydroxypropionicacid, i.e. greater ratios of oligomeric 3-hydroxypropionic acid tomonomeric 3-hydroxypropionic acid, facilitate the enrichment ofoligomeric 3-hydroxypropionic acid in the liquid phase.

The ratio of oligomeric 3-hydroxypropionic acid to monomeric3-hydroxypropionic acid in the context of this invention is the weightratio.

Advantageously, a polymerization inhibitor 1 is added to the liquidphase. Suitable polymerization inhibitors 1 are phenothiazine,hydroquinone and/or hydroquinone monomethyl ether. Very particularpreference is given to phenothiazine and hydroquinone monomethyl ether.In the case of use of a rectification column, the polymerizationinhibitor 1 is metered in at least partly via the reflux.

Advantageously, a polymerization inhibitor 2 is added to the aqueousacrylic acid. Suitable polymerization inhibitors 2 are phenothiazine,hydroquinone and/or hydroquinone monomethyl ether. Very particularpreference is given to phenothiazine and hydroquinone monomethyl ether.

The present invention is based on the finding that the propensity topolymerization can be reduced in the case of use of an inert organicsolvent 1. Possibly, the concentration of polymerizable acrylic acid issufficiently diluted.

It has also been found that, surprisingly, under the inventive reactionconditions, 3-hydroxypropionic acid preferentially forms oligomeric3-hydroxypropionic acid, and oligomeric 3-hydroxypropionic acid can beconverted readily to acrylic acid. Avoidance of oligomeric3-hydroxypropionic acid, as required in WO 2012/091114 A1, is thereforeunnecessary.

Oligomeric 3-hydroxypropionic acid is the product of at least two3-hydroxypropionic acid molecules. The molecules are joined here to oneanother by esterification of the carboxyl group of one molecule with thehydroxyl group of the other molecule.

Oligomeric acrylic acid is the product of at least two acrylic acidmolecules. The molecules are joined here to one another by Michaeladdition of the carboxyl group of one molecule to the ethylenic doublebond of the other molecule.

The process according to the invention is described hereinafter:

Preparation of 3-hydroxypropionic acid

In the process according to the invention, preference is given to usingaqueous 3-hydroxypropionic acid produced by fermentation. Such a processis disclosed, for example, in WO 02/090312 A1.

The aqueous 3-hydroxypropionic acid thus produced generally comprises,as well as water, essentially the following constituents:

-   -   35 to 70% by weight of 3-hydroxypropionic acid,    -   0 to 20% by weight of oligomeric 3-hydroxypropionic acid,    -   0 to 10% by weight of acrylic acid,    -   0 to 1% by weight of oligomeric acrylic acid,    -   0.01 to 0.1% by weight of glycolic acid,    -   0.01 to 0.1% by weight of 2-hydroxypropionic acid,    -   0.005 to 0.05% by weight of formic acid,    -   0.005 to 0.05% by weight of acetic acid,    -   0.005 to 0.05% by weight of succinic acid,    -   0.005 to 0.05% by weight of fumaric acid,    -   0.0001 to 0.01% by weight of formaldehyde,    -   0.0001 to 0.01% by weight of acetaldehyde,    -   0.0001 to 0.01% by weight of methanol and    -   0.0001 to 0.01% by weight of ethanol

Preparation of Acrylic Acid

The dehydration of 3-hydroxypropionic acid is performed in the liquidphase at a temperature of 120 to 300° C., preferably of 150 to 250° C.,more preferably of 170 to 230° C., most preferably of 180 to 220° C. Thepressure is not subject to any restrictions. A slightly reduced pressureis advantageous for safety reasons.

The liquid phase preferably comprises a polymerization inhibitor 1.Suitable polymerization inhibitors 1 are phenothiazine, hydroquinoneand/or hydroquinone monomethyl ether. Very particular preference isgiven to phenothiazine and hydroquinone monomethyl ether. The liquidphase comprises preferably from 0.001 to 5% by weight, more preferablyfrom 0.01 to 2% by weight and most preferably from 0.1 to 1% by weightof the polymerization inhibitor 1.

Advantageously, an oxygen-containing gas is additionally used to inhibitpolymerization. Particularly suitable for this purpose are air/nitrogenmixtures having an oxygen content of 6% by volume (lean air).

The liquid phase comprises 5 to 95% by weight, preferably from 10 to 90%by weight, more preferably from 20 to 80% by weight and most preferablyfrom 30 to 60% by weight of the inert organic solvent 1.

The boiling point of the inert organic solvent 1 at 1013 mbar is in therange from preferably 200 to 350° C., more preferably from 250 to 320°C., most preferably from 280 to 300° C. Suitable inert organic solvents1 are, for example dimethyl phthalate, diethyl phthalate, dimethylisophthalate, diethyl isophthalate, dimethyl terephthalate, diethylterephthalate, alkanoic acids such as nonanoic acid and decanoic acid,biphenyl and/or diphenyl ether.

The inert organic solvent 1 has a solubility in water at 23° C. ofpreferably less than 5 g per 100 ml of water, more preferably less than1 g per 100 ml of water and most preferably of less than 0.2 g per 100ml of water.

The dehydration may be base- or acid-catalyzed. Suitable basic catalystsare high-boiling tertiary amines, such as pentamethyldiethylenetriamine.Suitable acidic catalysts are high-boiling inorganic or organic acids,such as phosphoric acid and dodecylbenzenesulfonic acid. “High-boiling”here means a boiling point at 1013 mbar of preferably at least 160° C.,more preferably at least 180° C. and most preferably at least 190° C.

The amount of catalyst in the liquid phase is preferably from 1 to 60%by weight, more preferably from 2 to 40% by weight, most preferably from5 to 20% by weight.

The dehydration is performed continuously. The heat can be supplied viainternal and/or external heat exchangers of conventional design and/orvia jacket heating (the heat transfer medium used is advantageouslysteam). The heat is preferably supplied via external circulationevaporators with natural or forced circulation. Particular preference isgiven to using external circulation evaporators with forced circulation.Evaporators of this kind are described in EP 0 854 129 A1. The use of aplurality of evaporators, connected in series or in parallel, ispossible.

If an oxygen-containing gas is used to inhibit polymerization, this ispreferably supplied below the evaporator.

The feed to the reactor is preferably preheated to a temperature of 30to 100° C., more preferably of 40 to 95° C., very particularly of 50 to90° C.

The water/acrylic acid mixture formed in the dehydration is preferablyremoved by distillation, more preferably by means of a rectificationcolumn 1.

The rectification column 1 is of a design known per se and has thestandard internals. The column internals used may in principle be allstandard internals, for example trays, structured packings and/or randompackings. Among the trays, preference is given to bubble-cap trays,sieve trays, valve trays, Thormann trays and/or dual-flow trays; amongthe random packings, preference is given to those comprising rings,helices, saddles, Raschig, Intos or Pall rings, Berl or Intalox saddles,or braids. Particular preference is given to dual-flow trays.

In general, from 3 to 10 theoretical plates are sufficient in therectification column 1. The rectification is typically performed underslightly reduced pressure, preferably at a top pressure of 900 to 980mbar. The bottom pressure depends on the top pressure, the number andtype of column internals and the fluid-dynamic requirements of therectification.

The rectification column 1 is typically manufactured from austeniticsteel, preferably from material 1.4571 (to DIN EN 10020).

The aqueous acrylic acid removed at the top of the rectification column1 can be cooled indirectly, for example by means of heat exchangerswhich are known per se to those skilled in the art and are not subjectto any particular restriction, or directly, for example by means of aquench. It is preferably cooled by direct cooling. For this purpose,already condensed aqueous acrylic acid is cooled by means of a suitableheat exchanger and the cooled liquid is sprayed in the vapor above thewithdrawal point. This spraying can be effected in a separate apparatusor in the rectification unit itself. In the case of spraying in therectification unit, the withdrawal point for the aqueous acrylic acidadvantageously takes the form of a collecting tray. Internals whichimprove the mixing of the cooled aqueous acrylic acid with the vapor canenhance the effect of the direct cooling. All standard internals areuseful in principle for this purpose, for example trays, structuredpackings and/or random packings. Among the trays, preference is given tobubble-cap trays, sieve trays, valve trays, Thormann trays and/ordual-flow trays. Among the random packings, preference is given to thosecomprising rings, helices, saddles, Raschig, Intos or Pall rings, Berlor Intalox saddles, or braids. Particular preference is given todual-flow trays. In general, 2 to 5 theoretical plates are sufficienthere. These trays are not included in the figures given so far for thenumber of theoretical plates in the rectification column 1. The directcondensation of the aqueous acrylic acid can also be executed in morethan one stage, with temperature decreasing in the upward direction.

When a water-insoluble inert organic solvent 1 is used, the condenseddistillate from the rectification column 1 is separated by means of aphase separator. The organic phase can be recycled into therectification column 1, for example into the bottom. The aqueous phasemay likewise be partly recycled into the rectification column 1, forexample as a return stream and for direct cooling of the vapors.

The aqueous acrylic acid removed via the top of the rectification column1 generally comprises, as well as water and traces of the inert organicsolvent 1, essentially the following constituents:

-   -   0 to 0.001% by weight of 3-hydroxypropionic acid,    -   0 to 0.001% by weight of oligomeric 3-hydroxypropionic acid,    -   20 to 80% by weight of acrylic acid,    -   0 to 0.001% by weight of oligomeric acrylic acid,    -   0.001 to 1% by weight of glycolic acid,    -   0 to 0.001% by weight of 2-hydroxypropionic acid,    -   0.001 to 1% by weight of formic acid,    -   0.001 to 1% by weight of acetic acid,    -   0 to 0.001% by weight of succinic acid,    -   0 to 0.001% by weight of fumaric acid,    -   0.0001 to 0.05% by weight of formaldehyde,    -   0.0001 to 0.05% by weight of acetaldehyde,    -   0.0001 to 0.05% by weight of methanol and    -   0.0001 to 0.05% by weight of ethanol

A portion of the aqueous acrylic acid withdrawn, preferably 10 to 40% byweight based on the total amount of distillate, is used as reflux; theremainder of the aqueous acrylic acid is discharged.

The aqueous acrylic acid obtained in the dehydration can be worked up inan extraction column.

Advantageously, a portion of the liquid phase is withdrawn from thereactor, washed with water and, after phase separation, recycled. Theaqueous phase thus obtained can be discarded or, after furtherpurification steps, sent to the extraction column together with theaqueous acrylic acid withdrawn at the top of the rectification column 1.

The extraction column is of a design known per se and may have thestandard internals. Useful column internals in principle include allstandard internals. Examples are trays, structured packings and/orrandom packings. Among the trays, preference is given to sieve traysand/or dual-flow trays. Among the random packings, preference is givento those comprising rings, helices, saddles, Raschig, Intos or Pallrings, Berl or Intalox saddles, or braids. Particular preference isgiven to dual-flow trays. In general, 10 to 25 theoretical plates aresufficient here.

The extraction column is operated at a temperature of preferably 30 to70° C., more preferably 40 to 60° C., most preferably 45 to 55° C.

In the extraction column, acrylic acid is extracted from the aqueousphase by means of an inert organic solvent 2. The boiling point of theinert organic solvent 2 at 1013 mbar is in the range from preferably 200to 350° C., more preferably from 250 to 320° C., most preferably from280 to 300° C. Suitable inert organic solvents 2 are, for examplephthalic esters such as dimethyl phthalate and diethyl phthalate,isophthalic esters such as dimethyl isophthalate and diethylisophthalate, terephthalic esters such as dimethyl terephthalate anddiethyl terephthalate, alkanoic acids such as nonanoic acid and decanoicacid, biphenyl and/or diphenyl ether.

The inert organic solvent 2 has a solubility in water at 23° C. ofpreferably less than 5 g per 100 ml of water, more preferably less than1 g per 100 ml of water and most preferably of less than 0.2 g per 100ml of water.

The ratio of aqueous phase (aqueous acrylic acid) and organic phase(inert organic solvent 2) is preferably from 0.5:1 to 1.5:1. To maintainthe ratio, a portion of the aqueous extract can be recycled into theextraction column.

The aqueous extract removed at the top of the extraction column may bediscarded and generally comprises, as well as water and traces of theinert organic solvent and of any catalyst used, essentially thefollowing constituents:

-   -   0.005 to 0.1% by weight of 3-hydroxypropionic acid,    -   0.05 to 1% by weight of oligomeric 3-hydroxypropionic acid,    -   0.1 to 2% by weight of acrylic acid,    -   0.1 to 2% by weight of oligomeric acrylic acid,    -   0.01 to 1% by weight of glycolic acid,    -   0.01 to 1% by weight of 2-hydroxypropionic acid,    -   0.01 to 0.2% by weight of formic acid,    -   0.005 to 0.1% by weight of acetic acid,    -   0.01 to 0.2% by weight of succinic acid,    -   0.01 to 0.2% by weight of fumaric acid,    -   0.002% by weight of formaldehyde,    -   0 to 0.001% by weight of acetaldehyde,    -   0.0002 to 0.01% by weight of methanol and    -   0 to 0.002% by weight of ethanol

The organic extract removed at the base of the extraction columngenerally comprises, as well as the inert organic solvents and anycatalyst, essentially the following constituents:

-   -   0.0005 to 0.01% by weight of 3-hydroxypropionic acid,    -   0.01 to 1% by weight of oligomeric 3-hydroxypropionic acid,    -   1 to 5% by weight of water,    -   10 to 35% by weight of acrylic acid,    -   0.01 to 1% by weight of oligomeric acrylic acid,    -   0.005 to 0.5% by weight of glycolic acid,    -   0.005 to 0.2% by weight of 2-hydroxypropionic acid,    -   0.0001 to 0.1% by weight of formic acid,    -   0.001 to 0.1% by weight of acetic acid,    -   0.001 to 0.05% by weight of succinic acid,    -   0.001 to 0.1% by weight of fumaric acid,    -   0.0001 to 0.01% by weight of formaldehyde,    -   0.0001 to 0.005% by weight of acetaldehyde,    -   0.0001 to 0.005% by weight of methanol and    -   0.0001 to 0.01% by weight of ethanol

The organic extract obtained in the extraction can be worked up in arectification column 2.

The rectification column 2 is of a design known per se and has thestandard internals. The column internals used may in principle be allstandard internals, for example trays, structured packings and/or randompackings. Among the trays, preference is given to bubble-cap trays,sieve trays, valve trays, Thormann trays and/or dual-flow trays; amongthe random packings, preference is given to those comprising rings,helices, saddles, Raschig, Intos or Pall rings, Berl or Intalox saddles,or braids. Particular preference is given to dual-flow trays.

In general, from 10 to 25 theoretical plates are sufficient in therectification unit. The rectification is typically performed underreduced pressure, preferably at a top pressure of 70 to 140 mbar. Thebottom pressure depends on the top pressure, the number and type ofcolumn internals and the fluid-dynamic requirements of therectification, and is preferably 200 to 400 mbar.

The reflux of the rectification column 2 preferably comprises apolymerization inhibitor 2. Suitable polymerization inhibitors 2 arephenothiazine, hydroquinone and/or hydroquinone monomethyl ether. Veryparticular preference is given to phenothiazine. The reflux comprisespreferably from 0.0005 to 1% by weight, more preferably from 0.002 to0.5% by weight and most preferably from 0.01 to 0.1% by weight of thepolymerization inhibitor 1. Advantageously, an oxygen-containing gas isadditionally used to inhibit polymerization. Particularly suitable forthis purpose are air/nitrogen mixtures having an oxygen content of 6% byvolume (lean air).

The rectification column 2 is typically manufactured from austeniticsteel, preferably from material 1.4571 (to DIN EN 10020).

The feed into the rectification column 2 is appropriately effected inthe lower region thereof. It is preferably effected 2 to 5 theoreticalplates above the bottom of the rectification column 2. The feedtemperature is preferably from 20 to 200° C., more preferably from 50 to180° C. and most preferably from 80 to 160° C.

The heat is supplied via internal and/or external heat exchangers (theheat transfer medium is again preferably steam) of conventional designand/or via jacket heating. The heat is preferably supplied via externalcirculation evaporators with natural or forced circulation. Particularpreference is given to external circulation evaporators with forcedcirculation. Evaporators of this kind are described in EP 0 854 129 A1.The use of a plurality of evaporators, connected in series or inparallel, is possible. Preference is given to operating 2 to 4evaporators in parallel. The bottom temperature of the rectificationcolumn 2 is typically 180 to 250° C., preferably 195 to 235° C.

If an oxygen-containing gas is used to inhibit polymerization, this ispreferably supplied below the evaporator.

The high boiler fraction obtained in the bottoms of the rectificationcolumn 2 generally comprises, as well as the inert organic solvents andany catalyst, essentially the following constituents:

-   -   0.001 to 0.05% by weight of 3-hydroxypropionic acid,    -   0.01 to 1% by weight of oligomeric 3-hydroxypropionic acid,    -   0 to 0.0005% by weight of water,    -   0.01 to 1% by weight of acrylic acid,    -   0.01 to 1% by weight of oligomeric acrylic acid,    -   0.005 to 0.2% by weight of glycolic acid,    -   0.005 to 0.2% by weight of 2-hydroxypropionic acid,    -   0 to 0.0005% by weight of formic acid,    -   0 to 0.0005% by weight of acetic acid,    -   0.001 to 0.05% by weight of succinic acid,    -   0.001 to 0.1% by weight of fumaric acid,    -   0 to 0.0005% by weight of formaldehyde,    -   0 to 0.0005% by weight of acetaldehyde,    -   0 to 0.0005% by weight of methanol and    -   0 to 0.0005% by weight of ethanol

The bottoms liquid which comprises the inert organic solvent 2 and iswithdrawn from the rectification column 2 is recycled via a heatexchanger into the top region of the extraction column. The bottomsliquid is preferably conducted via a solids separator (cyclone) andoptionally supplemented with fresh inert organic solvent 2.

Above the feed into the rectification column 2, a crude acrylic acid iswithdrawn via a side draw, preferably 8 to 20 theoretical plates abovethe column bottom. The withdrawal of the crude acrylic acid is effectedin a customary manner and is not subject to any restriction. A suitableremoval method is via a collecting tray, in which case the entire refluxis collected and a portion is discharged and the other portion is usedas reflux below the collecting tray, or via a tray with integratedremoval means, preferably via a dual-flow tray with integrated removalmeans.

The crude acrylic acid withdrawn generally comprises, in addition toacrylic acid, essentially the following constituents:

-   -   0 to 0.0005% by weight of 3-hydroxypropionic acid,    -   0 to 0.0005% by weight of oligomeric 3-hydroxypropionic acid,    -   0 to 5% by weight of water,    -   0 to 0.0005% by weight of oligomeric acrylic acid,    -   0.001 to 0.02% by weight of glycolic acid,    -   0 to 0.0005% by weight of 2-hydroxypropionic acid,    -   0.005 to 0.01% by weight of formic acid,    -   0.01 to 0.2% by weight of acetic acid,    -   0 to 0.0005% by weight of succinic acid,    -   0 to 0.0005% by weight of fumaric acid,    -   0 to 0.0005% by weight of formaldehyde,    -   0 to 0.0005% by weight of acetaldehyde,    -   0 to 0.005% by weight of methanol and    -   0 to 0.005% by weight of ethanol

The crude acrylic acid withdrawn is cooled by means of a heat exchanger(an example of a suitable coolant is surface water). The use of aplurality of heat exchangers, connected in series or in parallel, ispossible. In the heat exchangers, which are known per se to thoseskilled in the art and are not subject to any particular restriction,the crude acrylic acid is preferably cooled to 40 to 90° C.

The crude acrylic acid withdrawn is discharged and some is used assolvent for the polymerization inhibitor 2.

The low boiler stream removed at the top of the rectification column 2can be cooled indirectly, for example by means of heat exchangers (thecoolant used may, for example, be surface water) which are known per seto those skilled in the art and are not subject to any particularrestriction, or directly, for example by means of a quench. It ispreferably removed by direct cooling. For this purpose, alreadycondensed low boiler fraction is cooled by means of a suitable heatexchanger and the cooled liquid is sprayed in the vapor above thewithdrawal point. This spraying can be effected in a separate apparatusor in the rectification column 2 itself. In the case of spraying in therectification column 2, the withdrawal point for the low boiler fractionadvantageously takes the form of a collecting tray. Internals whichimprove the mixing of the cooled low boiler fraction with the vapor canenhance the effect of the direct cooling. All standard internals areuseful in principle for this purpose, for example trays, structuredpackings and/or random packings. Among the trays, preference is given tobubble-cap trays, sieve trays, valve trays, Thormann trays and/ordual-flow trays. Among the random packings, preference is given to thosecomprising rings, helices, saddles, Raschig, Intos or Pall rings, Berlor Intalox saddles, or braids. Particular preference is given todual-flow trays. In general, 2 to 5 theoretical plates are sufficienthere. These trays are not included in the figures given so far for thenumber of theoretical plates in the rectification column 2. The directcondensation of the low boiler fraction can also be executed in morethan one stage, with temperature decreasing in the upward direction.

The low boiler stream removed via the top of the rectification column 2generally comprises, in addition to water, essentially the followingconstituents:

-   -   0 to 0.0005% by weight of 3-hydroxypropionic acid,    -   0 to 0.0005% by weight of oligomeric 3-hydroxypropionic acid,    -   10 to 60% by weight of acrylic acid,    -   0 to 0.0005% by weight of oligomeric acrylic acid,    -   0 to 0.0005% by weight of glycolic acid,    -   0 to 0.0005% by weight of 2-hydroxypropionic acid,    -   0.01 to 1% by weight of formic acid,    -   0.01 to 1% by weight of acetic acid,    -   0 to 0.0005% by weight of succinic acid,    -   0 to 0.0005% by weight of fumaric acid,    -   0.0005 to 0.02% by weight of formaldehyde,    -   0.0001 to 0.01% by weight of acetaldehyde,    -   0.0005 to 0.02% by weight of methanol and    -   0.005 to 0.05% by weight of ethanol

A portion of the liquid withdrawn as low boiler fraction is used asreflux; the remainder of the low boiler fraction is discharged andrecycled as aqueous phase into the extraction column.

The crude acrylic acid withdrawn from the rectification column 2 can beused directly for production of water-absorbing polymer particles.Preference is given to further purifying the crude acrylic acid bycrystallization. The mother liquor obtained in the crystallization canbe recycled into the rectification column 2, preferably below theremoval point for the crude acrylic acid.

The crude acrylic acid can be purified by layer crystallization, asdescribed, for example, in EP 0 616 998 A1, or by suspensioncrystallization, as described in DE 100 39 025 A1. Suspensioncrystallization is preferred. The combination of a suspensioncrystallization with a wash column, as described in WO 2003/041832 A1,is particularly preferred.

The acrylic acid thus purified generally comprises, in addition toacrylic acid, essentially the following constituents:

-   -   <0.0001% by weight of 3-hydroxypropionic acid,    -   <0.0001% by weight of oligomeric 3-hydroxypropionic acid,    -   0.01 to 0.05% by weight of water,    -   <0.0001% by weight of oligomeric acrylic acid,    -   <0.0001% by weight of glycolic acid,    -   <0.0001% by weight of 2-hydroxypropionic acid,    -   <0.0001% by weight of formic acid,    -   0.01 to 0.05% by weight of acetic acid,    -   <0.0001% by weight of succinic acid,    -   <0.0001% by weight of fumaric acid,    -   <0.0001% by weight of formaldehyde,    -   <0.0001% by weight of acetaldehyde,    -   <0.0001% by weight of methanol and    -   <0.0001% by weight of ethanol

The acrylic acid prepared by the process of the invention can be usedfor preparation of acrylic esters such as methyl acrylate, ethylacrylate, n-butyl acrylate and 2-ethylhexyl acrylate, and forpreparation of polymers such as water-absorbing polymer particles.

Production of Water-Absorbing Polymer Particles

Water-absorbing polymer particles are produced by polymerizing a monomersolution or suspension comprising

-   a) at least one ethylenically unsaturated monomer which bears acid    groups and may be at least partly neutralized, especially partly    neutralized acrylic acid,-   b) at least one crosslinker,-   c) at least one initiator,-   d) optionally one or more ethylenically unsaturated monomers    copolymerizable with the monomers mentioned under a) and-   e) optionally one or more water-soluble polymers,    and are typically water-insoluble.

The monomers a) are preferably water-soluble, i.e. the solubility inwater at 23° C. is typically at least 1 g/100 g of water, preferably atleast 5 g/100 g of water, more preferably at least 25 g/100 g of waterand most preferably at least 35 g/100 g of water.

Suitable monomers a) are, for example, ethylenically unsaturatedcarboxylic acids, such as acrylic acid, methacrylic acid and itaconicacid. Further suitable monomers a) are, for example, ethylenicallyunsaturated sulfonic acids, such as styrenesulfonic acid and2-acrylamido-2-methylpropanesulfonic acid (AMPS).

The proportion of acrylic acid and/or salts thereof in the total amountof monomers a) is preferably at least 50 mol %, more preferably at least90 mol %, most preferably at least 95 mol %.

Suitable crosslinkers b) are compounds having at least two groupssuitable for crosslinking. Such groups are, for example, ethylenicallyunsaturated groups which can be polymerized free-radically into thepolymer chain, and functional groups which can form covalent bonds withthe acid groups of the monomer a). In addition, polyvalent metal saltswhich can form coordinate bonds with at least two acid groups of themonomer a) are also suitable as crosslinkers b).

Crosslinkers b) are preferably compounds having at least twopolymerizable groups which can be polymerized free-radically into thepolymer network. Suitable crosslinkers b) are, for example, ethyleneglycol dimethacrylate, diethylene glycol diacrylate, polyethylene glycoldiacrylate, allyl methacrylate, trimethylolpropane triacrylate,triallylamine, tetraallylammonium chloride, tetraallyloxyethane, asdescribed in EP 0 530 438 A1, di- and triacrylates, as described in EP 0547 847 A1, EP 0 559 476 A1, EP 0 632 068 A1, WO 93/21237 A1, WO2003/104299 A1, WO 2003/104300 A1, WO 2003/104301 A1 and DE 103 31 450A1, mixed acrylates which, as well as acrylate groups, comprise furtherethylenically unsaturated groups, as described in DE 103 31 456 A1 andDE 103 55 401 A1, or crosslinker mixtures, as described, for example, inDE 195 43 368 A1, DE 196 46 484 A1, WO 90/15830 A1 and WO 2002/032962A2.

Preferred crosslinkers b) are pentaerythrityl triallyl ether,tetraallyloxyethane, methylenebismethacrylamide, 15-tuply ethoxylatedtrimethylolpropane triacrylate, polyethylene glycol diacrylate,trimethylolpropane triacrylate and triallylamine.

Very particularly preferred crosslinkers b) are the polyethoxylatedand/or -propoxylated glycerols which have been esterified with acrylicacid or methacrylic acid to give di- or triacrylates, as described, forexample, in WO 2003/104301 A1. Di- and/or triacrylates of 3- to 10-tuplyethoxylated glycerol are particularly advantageous. Very particularpreference is given to di- or triacrylates of 1- to 5-tuply ethoxylatedand/or propoxylated glycerol. Most preferred are the triacrylates of 3-to 5-tuply ethoxylated and/or propoxylated glycerol, especially thetriacrylate of 3-tuply ethoxylated glycerol.

The amount of crosslinker b) is preferably 0.05 to 1.5% by weight, morepreferably 0.1 to 1% by weight, most preferably 0.2 to 0.5% by weight,based in each case on monomer a). With rising crosslinker content, thecentrifuge retention capacity (CRC) falls and the absorption under apressure of 21.0 g/cm² passes through a maximum.

The initiators c) used may be all compounds which generate free radicalsunder the polymerization conditions, for example thermal initiators,redox initiators or photoinitiators. Suitable redox initiators aresodium peroxodisulfate/ascorbic acid, hydrogen peroxide/ascorbic acid,sodium peroxodisulfate/sodium bisulfite and hydrogen peroxide/sodiumbisulfite.

Preference is given to using mixtures of thermal initiators and redoxinitiators, such as sodium peroxodisulfate/hydrogen peroxide/ascorbicacid. The reducing component used is, however, preferably a mixture ofthe sodium salt of 2-hydroxy-2-sulfinatoacetic acid, the disodium saltof 2-hydroxy-2-sulfonatoacetic acid and sodium bisulfite. Such mixturesare obtainable as Brüggolite® FF6 and Brüggolite® FF7 (BrüggemannChemicals; Heilbronn; Germany).

Ethylenically unsaturated monomers d) copolymerizable with theethylenically unsaturated monomers a) bearing acid groups are, forexample, acrylamide, methacrylamide, hydroxyethyl acrylate, hydroxyethylmethacrylate, dimethylaminoethyl methacrylate, dimethylaminoethylacrylate, dimethylaminopropyl acrylate, diethylaminopropyl acrylate,dimethylaminoethyl methacrylate, diethylaminoethyl methacrylate.

The water-soluble polymers e) used may be polyvinyl alcohol,polyvinylpyrrolidone, starch, starch derivatives, modified cellulose,such as methyl cellulose or hydroxyethyl cellulose, gelatin, polyglycolsor polyacrylic acids, preferably starch, starch derivatives and modifiedcellulose.

Typically, an aqueous monomer solution is used. The water content of themonomer solution is preferably from 40 to 75% by weight, more preferablyfrom 45 to 70% by weight and most preferably from 50 to 65% by weight.It is also possible to use monomer suspensions, i.e. monomer solutionswith excess monomer a), for example sodium acrylate. With rising watercontent, the energy requirement in the subsequent drying rises, and,with falling water content, the heat of polymerization can only beremoved inadequately.

For optimal action, the polymerization inhibitors typically used inacrylic acid require dissolved oxygen. The monomer solution cantherefore be freed of dissolved oxygen before the polymerization byinertization, i.e. flowing an inert gas through, preferably nitrogen orcarbon dioxide. The oxygen content of the monomer solution is preferablylowered before the polymerization to less than 1 ppm by weight, morepreferably to less than 0.5 ppm by weight, most preferably to less than0.1 ppm by weight.

Suitable reactors are, for example, kneading reactors or belt reactors.In the kneader, the polymer gel formed in the polymerization of anaqueous monomer solution or suspension is comminuted continuously by,for example, contrarotatory stirrer shafts, as described in WO2001/038402 A1. Polymerization on a belt is described, for example, inDE 38 25 366 A1 and U.S. Pat. No. 6,241,928. Polymerization in a beltreactor forms a polymer gel which has to be comminuted in a furtherprocess step, for example in an extruder or kneader.

To improve the drying properties, the comminuted polymer gel obtained bymeans of a kneader can additionally be extruded.

However, it is also possible to dropletize an aqueous monomer solutionand to polymerize the droplets obtained in a heated carrier gas stream.It is possible here to combine the process steps of polymerization anddrying, as described in WO 2008/040715 A2, WO 2008/052971 A1 and WO2011/026876 A1.

The acid groups of the resulting polymer gels have typically beenpartially neutralized. Neutralization is preferably carried out at themonomer stage. This is typically accomplished by mixing in theneutralizing agent as an aqueous solution or preferably also as a solid.The degree of neutralization is preferably from 25 to 95 mol %, morepreferably from 30 to 80 mol % and most preferably from 40 to 75 mol %,for which the customary neutralizing agents can be used, preferablyalkali metal hydroxides, alkali metal oxides, alkali metal carbonates oralkali metal hydrogencarbonates and also mixtures thereof. Instead ofalkali metal salts, it is also possible to use ammonium salts.Particularly preferred alkali metals are sodium and potassium, but veryparticular preference is given to sodium hydroxide, sodium carbonate orsodium hydrogencarbonate and also mixtures thereof.

However, it is also possible to carry out neutralization after thepolymerization, at the stage of the polymer gel formed in thepolymerization. It is also possible to neutralize up to 40 mol %,preferably 10 to 30 mol % and more preferably 15 to 25 mol % of the acidgroups before the polymerization by adding a portion of the neutralizingagent directly to the monomer solution and setting the desired finaldegree of neutralization only after the polymerization, at the polymergel stage. When the polymer gel is at least partly neutralized after thepolymerization, the polymer gel is preferably comminuted mechanically,for example by means of an extruder, in which case the neutralizingagent can be sprayed, sprinkled or poured on and then carefully mixedin. To this end, the gel mass obtained can be repeatedly extruded forhomogenization.

The polymer gel is then preferably dried with a belt drier until theresidual moisture content is preferably 0.5 to 15% by weight, morepreferably 1 to 10% by weight and most preferably 2 to 8% by weight, theresidual moisture content being determined by EDANA recommended testmethod No. WSP 230.2-05 “Mass Loss Upon Heating”. In the case of toohigh a residual moisture content, the dried polymer gel has too low aglass transition temperature T_(g) and can be processed further onlywith difficulty. In the case of too low a residual moisture content, thedried polymer gel is too brittle and, in the subsequent comminutionsteps, undesirably large amounts of polymer particles with anexcessively low particle size are obtained (“fines”). The solids contentof the gel before the drying is preferably from 25 to 90% by weight,more preferably from 35 to 70% by weight and most preferably from 40 to60% by weight. However, a fluidized bed drier or a paddle drier mayoptionally also be used for drying purposes.

Thereafter, the dried polymer gel is ground and classified, and theapparatus used for grinding may typically be single or multistage rollmills, preferably two- or three-stage roll mills, pin mills, hammermills or vibratory mills.

The mean particle size of the polymer particles removed as the productfraction is preferably at least 200 μm, more preferably from 250 to 600μm and very particularly from 300 to 500 μm. The mean particle size ofthe product fraction may be determined by means of EDANA recommendedtest method No. WSP 220.2-05 “Particle Size Distribution”, where theproportions by mass of the screen fractions are plotted in cumulatedform and the mean particle size is determined graphically. The meanparticle size here is the value of the mesh size which gives rise to acumulative 50% by weight.

The proportion of particles having a particle size of greater than 150μm is preferably at least 90% by weight, more preferably at least 95% byweight and most preferably at least 98% by weight.

Polymer particles with too small a particle size lower the permeability(SFC). The proportion of excessively small polymer particles (“fines”)should therefore be low.

Excessively small polymer particles are therefore typically removed andrecycled into the process. This is preferably done before, during orimmediately after the polymerization, i.e. before the drying of thepolymer gel. The excessively small polymer particles can be moistenedwith water and/or aqueous surfactant before or during the recycling.

It is also possible to remove excessively small polymer particles inlater process steps, for example after the surface postcrosslinking oranother coating step. In this case, the excessively small polymerparticles recycled are surface postcrosslinked or coated in another way,for example with fumed silica.

If a kneading reactor is used for polymerization, the excessively smallpolymer particles are preferably added during the last third of thepolymerization.

If the excessively small polymer particles are added at a very latestage, for example not until an apparatus connected downstream of thepolymerization reactor, for example an extruder, the excessively smallpolymer particles can be incorporated into the resulting polymer gelonly with difficulty. Insufficiently incorporated, excessively smallpolymer particles are, however, detached again from the dried polymergel during the grinding, are therefore removed again in the course ofclassification and increase the amount of excessively small polymerparticles to be recycled.

The proportion of particles having a particle size of at most 850 μm ispreferably at least 90% by weight, more preferably at least 95% byweight, most preferably at least 98% by weight.

The proportion of particles having a particle size of at most 600 μm ispreferably at least 90% by weight, more preferably at least 95% byweight, most preferably at least 98% by weight.

Polymer particles of excessively large particle size lower the freeswell rate. The proportion of excessively large polymer particles shouldtherefore likewise be low.

Excessively large polymer particles are therefore typically removed andrecycled into the grinding of the dried polymer gel.

To further improve the properties, the polymer particles can be surfacepostcrosslinked. Suitable surface postcrosslinkers are compounds whichcomprise groups which can form covalent bonds with at least twocarboxylate groups of the polymer particles. Suitable compounds are, forexample, polyfunctional amines, polyfunctional amido amines,polyfunctional epoxides, as described in EP 0 083 022 A2, EP 0 543 303A1 and EP 0 937 736 A2, di- or polyfunctional alcohols, as described inDE 33 14 019 A1, DE 35 23 617 A1 and EP 0 450 922 A2, orβ-hydroxyalkylamides, as described in DE 102 04 938 A1 and U.S. Pat. No.6,239,230.

Additionally described as suitable surface postcrosslinkers are cycliccarbonates in DE 40 20 780 C1, 2-oxazolidinone and derivatives thereof,such as 2-hydroxyethyl-2-oxazolidinone, in DE 198 07 502 A1, bis- andpoly-2-oxazolidinones in DE 198 07 992 C1, 2-oxotetrahydro-1,3-oxazineand derivatives thereof in DE 198 54 573 A1, N-acyl-2-oxazolidinones inDE 198 54 574 A1, cyclic ureas in DE 102 04 937 A1, bicyclic amidoacetals in DE 103 34 584 A1, oxetanes and cyclic ureas in EP 1 199 327A2 and morpholine-2,3-dione and derivatives thereof in WO 2003/031482A1.

Preferred surface postcrosslinkers are ethylene carbonate, ethyleneglycol diglycidyl ether, reaction products of polyamides withepichlorohydrin and mixtures of propylene glycol and 1,4-butanediol.

Very particularly preferred surface postcrosslinkers are2-hydroxyethyl-2-oxazolidinone, 2-oxazolidinone and 1,3-propanediol.

In addition, it is also possible to use surface postcrosslinkers whichcomprise additional polymerizable ethylenically unsaturated groups, asdescribed in DE 37 13 601 A1.

The amount of surface postcrosslinker is preferably 0.001 to 5% byweight, more preferably 0.02 to 2% by weight and most preferably 0.05 to1% by weight, based in each case on the polymer particles.

In a preferred embodiment of the present invention, polyvalent cationsare applied to the particle surface in addition to the surfacepostcrosslinkers before, during or after the surface postcrosslinking.

The polyvalent cations usable in the process according to the inventionare, for example, divalent cations such as the cations of zinc,magnesium, calcium, iron and strontium, trivalent cations such as thecations of aluminum, iron, chromium, rare earths and manganese,tetravalent cations such as the cations of titanium and zirconium.Possible counterions are hydroxide, chloride, bromide, sulfate,hydrogensulfate, carbonate, hydrogencarbonate, nitrate, phosphate,hydrogenphosphate, dihydrogenphosphate and carboxylate, such as acetate,citrate and lactate. Salts with different counterions are also possible,for example basic aluminum salts such as aluminum monoacetate oraluminum monolactate. Aluminum sulfate, aluminum monoacetate andaluminum lactate are preferred. Apart from metal salts, it is alsopossible to use polyamines as polyvalent cations.

The amount of polyvalent cation used is, for example, 0.001 to 1% byweight, preferably 0.005 to 0.5% by weight and more preferably 0.02 to0.2% by weight, based in each case on the polymer particles.

The surface postcrosslinking is typically performed in such a way that asolution of the surface postcrosslinker is sprayed onto the driedpolymer particles. After the spray application, the polymer particlescoated with surface postcrosslinker are dried thermally, and the surfacepostcrosslinking reaction can take place either before or during thedrying.

The spray application of a solution of the surface postcrosslinker ispreferably performed in mixers with moving mixing tools, such as screwmixers, disk mixers and paddle mixers. Particular preference is given tohorizontal mixers such as paddle mixers, very particular preference tovertical mixers. The distinction between horizontal mixers and verticalmixers is made by the position of the mixing shaft, i.e. horizontalmixers have a horizontally mounted mixing shaft and vertical mixers avertically mounted mixing shaft. Suitable mixers are, for example,horizontal Pflugschar® plowshare mixers (Gebr. Lödige Maschinenbau GmbH;Paderborn; Germany), Vrieco-Nauta continuous mixers (Hosokawa Micron BV;Doetinchem; the Netherlands), Processall Mixmill mixers (ProcessallIncorporated; Cincinnati; USA) and Schugi Flexomix® (Hosokawa Micron BV;Doetinchem; the Netherlands). However, it is also possible to spray onthe surface postcrosslinker solution in a fluidized bed.

The surface postcrosslinkers are typically used in the form of anaqueous solution. The penetration depth of the surface postcrosslinkerinto the polymer particles can be adjusted via the content of nonaqueoussolvent and total amount of solvent.

When exclusively water is used as the solvent, a surfactant isadvantageously added. This improves the wetting characteristics andreduces the tendency to form lumps. However, preference is given tousing solvent mixtures, for example isopropanol/water,1,3-propanediol/water and propylene glycol/water, where the mixing ratioin terms of mass is preferably from 20:80 to 40:60.

The thermal drying is preferably carried out in contact driers, morepreferably paddle driers, most preferably disk driers. Suitable driersare, for example, Hosokawa Bepex® Horizontal Paddle Dryers (HosokawaMicron GmbH; Leingarten; Germany), Hosokawa Bepex® Disc Dryers (HosokawaMicron GmbH; Leingarten; Germany), Holo-Flite® driers (Metso MineralsIndustries Inc.; Danville; USA) and Nara Paddle Dryers (NARA MachineryEurope; Frechen; Germany). Moreover, fluidized bed driers may also beused.

The drying can be effected in the mixer itself, by heating the jacket orblowing in warm air. Equally suitable is a downstream drier, for examplea shelf drier, a rotary tube oven or a heatable screw. It isparticularly advantageous to effect mixing and drying in a fluidized beddrier.

Preferred drying temperatures are in the range of 100 to 250° C.,preferably 120 to 220° C., more preferably 130 to 210° C. and mostpreferably 150 to 200° C. The preferred residence time at thistemperature in the reaction mixer or drier is preferably at least 10minutes, more preferably at least 20 minutes, most preferably at least30 minutes, and typically at most 60 minutes.

In a preferred embodiment of the present invention, the water-absorbingpolymer particles are cooled after the thermal drying. The cooling ispreferably performed in contact coolers, more preferably paddle coolersand most preferably disk coolers. Suitable coolers are, for example,Hosokawa Bepex® Horizontal Paddle Coolers (Hosokawa Micron GmbH;Leingarten; Germany), Hosokawa Bepex® Disc Coolers (Hosokawa MicronGmbH; Leingarten; Germany), Holo-Flite® coolers (Metso MineralsIndustries Inc.; Danville; USA) and Nara Paddle Coolers (NARA MachineryEurope; Frechen; Germany). Moreover, fluidized bed coolers may also beused.

In the cooler, the water-absorbing polymer particles are cooled to 20 to150° C., preferably 30 to 120° C., more preferably 40 to 100° C. andmost preferably 50 to 80° C.

Subsequently, the surface postcrosslinked polymer particles can beclassified again, excessively small and/or excessively large polymerparticles being removed and recycled into the process.

To further improve the properties, the surface postcrosslinked polymerparticles can be coated or remoisturized.

The remoisturizing is preferably performed at 30 to 80° C., morepreferably at 35 to 70° C., most preferably at 40 to 60° C. Atexcessively low temperatures, the water-absorbing polymer particles tendto form lumps, and, at higher temperatures, water already evaporates toa noticeable degree. The amount of water used for remoisturizing ispreferably from 1 to 10% by weight, more preferably from 2 to 8% byweight and most preferably from 3 to 5% by weight, based in each case onthe water-absorbing polymer particles. The remoisturizing increases themechanical stability of the polymer particles and reduces their tendencyto static charging. The remoisturizing is advantageously performed inthe cooler after the thermal drying.

Suitable coatings for improving the free swell rate and the permeability(SFC) are, for example, inorganic inert substances, such aswater-insoluble metal salts, organic polymers, cationic polymers and di-or polyvalent metal cations. Suitable coatings for dust binding are, forexample, polyols. Suitable coatings for counteracting the undesiredcaking tendency of the polymer particles are, for example, fumed silica,such as Aerosil® 200, and surfactants, such as Span® 20.

The present application further provides an aqueous acrylic acidprepared by the process according to the invention, wherein the aqueous3-hydroxypropionic acid has been prepared by fermentation.

The present application further provides the aqueous acrylic acidremoved from the dehydration.

The inventive aqueous acrylic acid preferably comprises water and

20 to 80% by weight of acrylic acid,0.001 to 1% by weight of formic acid,0.001 to 1% by weight of acetic acid,0.001 to 1% by weight of glycolic acid,0.0001 to 0.05% by weight of formaldehyde,0.0001 to 0.05% by weight of acetaldehyde,0.0001 to 0.05% by weight of methanol,0.0001 to 0.05% by weight of ethanol and0.0001 to 0.1% by weight of an inert organic solvent 1.

The inventive aqueous acrylic acid comprises more preferably water and

30 to 70% by weight of acrylic acid,0.005 to 0.5% by weight of formic acid,0.005 to 0.5% by weight of acetic acid,0.005 to 0.5% by weight of glycolic acid,0.0002 to 0.02% by weight of formaldehyde,0.0002 to 0.02% by weight of acetaldehyde,0.0002 to 0.02% by weight of methanol,0.0002 to 0.02% by weight of ethanol and0.0005 to 0.05% by weight of an inert organic solvent 1.

The inventive aqueous acrylic acid comprises most preferably water and

40 to 60% by weight of acrylic acid,0.01 to 0.1% by weight of formic acid,0.01 to 0.1% by weight of acetic acid,0.01 to 0.1% by weight of glycolic acid,0.0005 to 0.01% by weight of formaldehyde,0.0005 to 0.01% by weight of acetaldehyde,0.0005 to 0.01% by weight of methanol,0.0005 to 0.01% by weight of ethanol and0.001 to 0.02% by weight of an inert organic solvent 1.

The inert organic solvent is preferably selected from dimethylphthalate, diethyl phthalate, dimethyl isophthalate, diethylisophthalate, dimethyl terephthalate, diethyl terephthalate, nonanoicacid, decanoic acid, biphenyl and/or diphenyl ether.

Methods Determination of the 3-hydroxypropionic acid and acrylic acidcontents

The 3-hydroxypropionic acid and acrylic acid contents are determined byreverse phase chromatography with ultraviolet detection.

The sample is prepared by weighing about 100 to 300 mg of sample into a50 ml standard flask and making it up to the mark with eluent A. EluentA is a mixture of 1000 ml of water and 1 ml of 0.5 molar sulfuric acid.

For calibration of 3-hydroxypropionic acid, four weights (about 280 mg,180 mg, 90 mg and 60 mg) are used, with acidification (possiblyre-acidification) to a pH of 3 to 4 with about 100 μl of 25% by weightsulfuric acid before making up to the mark of the 50 ml standard flask.The calibration range is 0.1 to 280 mg/50 ml.

For calibration of acrylic acid, at least two weights are diluted to atleast six concentrations. The calibration range is 0.01 to 0.9 mg/50 ml.

For reverse phase chromatography, a separating column of the Prontosil120-3-C18 AQ 3 μm, 150×4.6 mm (BISCHOFF Analysentechnik and -geräteGmbH, Leonberg, Germany) type is used. The temperature is 25° C., theinjection volume is 50 μl, the flow rate is 1.5 ml/min and the run timeis 15 minutes. The UV detector is set to 205 nm. From the start to 8minutes 100% by weight of eluent A is used, from 8 to 11.5 minutes amixture of 40% by weight of eluent A and 60% by weight of eluent B, andfrom 11.5 minutes to the end 100% by weight of eluent A. Eluent B isacetonitrile.

Determination of the oligomeric 3-hydroxypropionic acid and oligomericacrylic acid contents

The oligomeric 3-hydroxypropionic acid and oligomeric acrylic acidcontents are determined by ion exclusion chromatography with refractiveindex detection.

To prepare the samples, the components to be analyzed are separated fromthe sample matrix by means of a solid phase extraction. For thispurpose, an SPE cartridge of the Bakerband SiOH 6 ml, 1000 mg (J. T.Baker, Avantor Performance Materials, Inc., Center Valley, Pa., USA)type is used. The SPE cartridge is activated with 6 ml of methanol andflushed twice with 6 ml each time of eluent. The SPE cartridge mustnever run dry. Subsequently, the sample is pipetted onto the SPEcartridge and flushed 10 times with 1 ml of eluent each time into a 10ml standard flask. The amount of sample used is 65 μl in the case ofbottoms samples, 85 μl in the case of tops samples and 75 μl in the caseof extract samples. Unless the samples comprise hydrophobic solvent(inert organic solvent 1, inert organic solvent 2), these samples can beapplied without extraction; for this purpose, 85 μl are dissolveddirectly in 10 ml of eluent. The eluent used is 0.1% by volume aqueousphosphoric acid.

For ion exclusion chromatography, two separating columns of the ShodexRSpak KC-811, 300×8 mm (SHOWA DENKO K.K. Shodex (Separation & HPLC)Group, Kawasaki, Japan) type are used connected in series. Thetemperature is 40° C., the injection volume is 100 μl, the flow rate is1.0 ml/min and the run time is 45 minutes. The eluent used is 0.1% byweight aqueous phosphoric acid. The autosampler is cooled to 15° C.

For evaluation, the integration is preceded by a blank valuesubtraction. For this purpose, eluent is injected and the chromatogramthus obtained is subtracted from the sample chromatogram. The evaluationis effected in terms of area percent, with conversion to percent byweight by means of the following formula:

${{Weight}\mspace{14mu} \% ({oligomer})} = {\frac{{Weight}\mspace{14mu} \% ({monomer})}{{Area}\mspace{14mu} \% ({monomer})} \times {Area}\mspace{14mu} \% ({oligomer})}$

To evaluate the oligomers, the contents of the dimers, trimers,tetramers and pentamers (i.e. n=2 to 5) are added up in each case. Theretention times are monitored by injecting 3-hydroxypropionic acid anddiacrylic acid.

EXAMPLES Example 1

A jacketed 2 l three-neck flask with distillation attachment wasinitially charged with 1500 g of an about 30% by weight aqueous3-hydroxypropionic acid, water was distilled off at 100 mbar for 3 hoursand the remaining residue was distilled at 40 mbar. The jacket washeated by means of heat transfer oil. The composition of distillate anddistillation residue was analyzed.

TABLE 1 Composition of the distillate Oligo-AA 3HPA AA Oligo-3HPA [% byTime [h] [% by weight] [% by weight] [% by weight] weight] 2.9 36.5 9.32.1 0.0 5.5 38.2 19.4 6.3 1.6 6.7 12.1 51.5 6.0 20.2 7.6 2.2 62.1 5.826.8 8.8 0.5 57.6 0.2 41.4

TABLE 2 Composition of the distillation residue 3HPA AA Oligo-3HPAOligo-AA Temperature [% by [% by [% by [% by Time [h] [° C.] weight]weight] weight] weight] 2.9 154 42.3 0.2 41.5 9.3 5.5 180 16.3 0.2 55.921.5 6.7 221 1.7 0.3 56.9 37.7 7.6 224 0.3 0.3 38.0 59.7 8.8 230 0.1 0.431.2 58.1 3HPA 3-hydroxypropionic acid AA acrylic acid Oligo-3HPAoligomeric 3-hydroxypropionic acid Oligo-AA oligomeric acrylic acid

The results show that, in the distillation residue, 3-hydroxypropionicacid is first converted to oligomeric 3-hydroxypropionic acid. Onlythereafter is there significant formation of acrylic acid and oligomericacrylic acid. The dehydration of 3-hydroxypropionic acid probablyproceeds via oligomeric 3-hydroxypropionic acid as an intermediate. Fora high yield and a high selectivity, 3-hydroxypropionic acid thereforehas to be converted to oligomeric 3-hydroxypropionic acid. Thus,residence times sufficient for dehydration are necessary.

Example 2

The dehydration (1) was conducted in a reactor with a forced circulationflash evaporator and connected rectification column 1.

The reactor used was a 3 l jacketed glass vessel. The amount of liquidin the reactor was about 2500 g. This corresponds to a residence time ofabout 5 hours. The temperature in the reactor was 160° C. The reactorwas simultaneously the bottom of the rectification column 1.

The forced circulation flash evaporator consisted of a pump, a heatexchanger and a pressure-retaining valve. The reactor contents werecirculated by means of the pump through the heat exchanger and thepressure-retaining valve. The heat exchanger consisted of 2 jacketedpipes having a length of 1000 mm and an internal area of 0.074 m².

The rectification column was electrically trace-heated and had aninternal diameter of 50 mm. As separating internals were fabric packingsof the Rhombopak 9M type (Sulzer Chemtech, Winterthur, Switzerland) Theheight of the fabric packings was 500 mm. The vapor was condensed in twostages and separated by means of a decanter into an organic phase and anaqueous phase.

The aqueous solution used for dehydration comprised

76.5% by weight of water,0.02% by weight of acrylic acid,0.32% by weight of oligomeric acrylic acid,19.9% by weight of 3-hydroxypropionic acid and3.24% by weight of oligomeric 3-hydroxypropionic acid.

500 g/h of the aqueous solution and 25 g/h of a mixture of 94% by weightof dimethyl phthalate and 6% by weight of pentamethyldiethylenetriaminewere preheated to 48° C. and metered in upstream of the heat exchangerof the forced circulation flash evaporator.

Through the forced circulation flash evaporator, a further 249 kg/h ofreactor contents were circulated. Upstream of the pressure-retainingvalve, the pressure was 1.608 bar and the temperature 168° C. 27 g/h ofreactor contents were discharged from the circuit and discarded.

The discharged reactor contents comprised

1.5% by weight of water,7.2% by weight of acrylic acid,12.8% by weight of oligomeric acrylic acid,1.1% by weight of 3-hydroxypropionic acid and8.7% by weight of oligomeric 3-hydroxypropionic acid.

The temperature at the top of the rectification column 1 was 108° C. Thevapor was cooled directly in a first cooler with 5 kg/h of aqueous phasefrom the decanter. The offgas from the first cooler was cooledindirectly in a second cooler (aftercooler). The offgas from the secondcooler had a temperature of 24° C. and a pressure of 949 mbar.

From the decanter, 2.0 l/h of aqueous phase were recycled as returnstream into the rectification column 1, and 524 g/h were discharged asproduct. The organic phase was metered in beyond the pump of the forcedcirculation flash evaporator.

The discharged aqueous phase comprised

76.2% by weight of water,21.8% by weight of acrylic acid,0.8% by weight of oligomeric acrylic acid,0.1% by weight of 3-hydroxypropionic acid and1.1% by weight of dimethyl phthalate.

25 g/h of an aqueous acrylic acid were metered into the decanter. Theaqueous acrylic acid comprised 49% by weight of water, 49% by weight ofacrylic acid, 1% by weight of phenothiazine and 1% by weight ofhydroquinone monomethyl ether. The aqueous acrylic acid still comprisedundissolved components, probably phenothiazine.

Example 3

The dehydration (1) is performed in a jacketed 10 l glass vessel. Via abase outlet, the contents of the glass vessel are circulated by means ofa pump through a shell-and-tube heat exchanger. The glass vessel isinitially charged with 4000 g of a mixture of 85% by weight of diphyland 15% by weight of pentamethyldiethylenetriamine. Diphyl is theeutectic mixture of diphenyl ether and biphenyl. The glass vessel isabout 80% full in the steady state. Below the shell-and-tube heatexchanger, 2 l/h of air are metered into the circuit.

The feed used is 1571 g/h of aqueous 3-hydroxypropionic acid, preparedaccording to WO 2012/074818 A2. The aqueous 3-hydroxypropionic acid hasthe following composition:

-   -   45.0% by weight of 3-hydroxypropionic acid,    -   12.0% by weight of oligomeric 3-hydroxypropionic acid,    -   40.7% by weight of water,    -   2.0% by weight of acrylic acid,    -   0.1% by weight of oligomeric acrylic acid,    -   0.06% by weight of glycolic acid,    -   0.05% by weight of 2-hydroxypropionic acid,    -   0.02% by weight of formic acid,    -   0.02% by weight of acetic acid,    -   0.02% by weight of succinic acid,    -   0.02% by weight of fumaric acid,    -   0.004% by weight of formaldehyde,    -   0.002% by weight of acetaldehyde,    -   0.002% by weight of methanol and    -   0.002% by weight of ethanol

The reaction temperature in the glass vessel is 180° C.; the pressure inthe glass vessel is 950 mbar.

20.8 g/h of residue are withdrawn from the glass vessel. The residue isextracted with 25.0 g/h of water and the organic phase is recycled intothe glass vessel. Losses of diphyl and pentamethyldiethylenetriamine arereplaced regularly. The target values in the liquid phase for diphyl andpentamethyldiethylenetriamine are about 40% by weight and about 8% byweight. The aqueous phase is sent to the extraction (2).

A 25-tray bubble-cap tray column having an internal diameter of 50 mm isplaced atop the glass vessel. The bubble-cap tray column has anelectrical guard heater.

Between the 20th and 21st trays of the bubble-cap tray column isinstalled a collecting tray. The liquid is withdrawn completelytherefrom and conveyed by means of a pump through a heat exchanger, inthe course of which it is cooled to 35° C., and is recycled to the 25thtray of the bubble-cap tray column. 1557 g/h of the cooled liquid aresent to the extraction (2). 493 g/h of the cooled liquid are recycled tothe 20th tray of the bubble-cap tray column. The reflux is stabilizedwith 0.005% by weight of phenothiazine.

The liquid withdrawn from the 20th tray of the bubble-cap tray columnhas the following composition:

-   -   <0.0001% by weight of 3-hydroxypropionic acid,    -   <0.0001% by weight of oligomeric 3-hydroxypropionic acid,    -   51.2% by weight of water,    -   48.7% by weight of acrylic acid,    -   <0.0001% by weight of oligomeric acrylic acid,    -   0.045% by weight of glycolic acid,    -   <0.0001% by weight of 2-hydroxypropionic acid,    -   0.02% by weight of formic acid,    -   0.02% by weight of acetic acid,    -   <0.0001% by weight of succinic acid,    -   <0.0001% by weight of fumaric acid,    -   0.003% by weight of formaldehyde,    -   <0.0001% by weight of acetaldehyde,    -   0.001% by weight of methanol,    -   0.001% by weight of ethanol,    -   <0.0001% by weight of pentamethyldiethylenetriamine and    -   0.01% by weight of diphyl

The extraction (2) is performed in a 20-tray sieve tray column with aninternal diameter of 50 mm. The aqueous phases from the dehydration (1)are heated to 50° C. and sent to the sieve tray column at the base. Thefeed of aqueous phase totals 2830 g/h. At the top of the sieve traycolumn, 2809 g/h of liquid from the bottom of the distillation (3) and21 g/h of dimethyl phthalate with a temperature of 50° C. as extractantare fed in.

1024 g/h of the aqueous extract withdrawn at the top of the sieve traycolumn are recycled at the base of the sieve tray column. The rest ofthe aqueous extract is discarded.

The aqueous extract withdrawn at the top of the sieve tray column hasthe following composition:

-   -   0.02% by weight of 3-hydroxypropionic acid,    -   0.3% by weight of oligomeric 3-hydroxypropionic acid,    -   96.8% by weight of water,    -   0.6% by weight of acrylic acid,    -   0.5% by weight of oligomeric acrylic acid,    -   0.1% by weight of glycolic acid,    -   0.1% by weight of 2-hydroxypropionic acid,    -   0.05% by weight of formic acid,    -   0.025% by weight of acetic acid,    -   0.05% by weight of succinic acid,    -   0.05% by weight of fumaric acid,    -   0.0035% by weight of formaldehyde,    -   <0.0001% by weight of acetaldehyde,    -   0.001% by weight of methanol,    -   0.0003% by weight of ethanol,    -   0.2% by weight of pentamethyldiethylenetriamine,    -   0.0002% by weight of diphyl and    -   1.2% by weight of dimethyl phthalate

At the base of the sieve tray column, 3799 g/h of organic extract arewithdrawn and transferred into the distillation (3).

The organic extract withdrawn at the base of the sieve tray column hasthe following composition:

-   -   0.002% by weight of 3-hydroxypropionic acid,    -   0.1% by weight of oligomeric 3-hydroxypropionic acid,    -   3.7% by weight of water,    -   22.2% by weight of acrylic acid,    -   0.5% by weight of oligomeric acrylic acid,    -   0.06% by weight of glycolic acid,    -   0.035% by weight of 2-hydroxypropionic acid,    -   0.006% by weight of formic acid,    -   0.02% by weight of acetic acid,    -   0.005% by weight of succinic acid,    -   0.008% by weight of fumaric acid,    -   0.002% by weight of formaldehyde,    -   0.0005% by weight of acetaldehyde,    -   0.0005% by weight of methanol,    -   0.001% by weight of ethanol and    -   0.06% by weight of pentamethyldiethylenetriamine,    -   1.5% by weight of diphyl and    -   71.8% by weight of dimethyl phthalate

The distillation (3) is performed in a 30-tray bubble-cap tray columnhaving an internal diameter of 50 mm. The bubble-cap tray column has anelectrical guard heater.

The feed to the distillation (3) is heated to 160° C. and fed to the 5thtray of the bubble-cap tray column.

The bottoms liquid of the bubble-cap tray column is circulated by meansof a pump through a shell-and-tube heat exchanger. Below theshell-and-tube heat exchanger, 2 l/h of air are metered into thecircuit. The temperature and pressure in the bottom of the bubble-captray column are 220° C. and 265 mbar.

2809 g/h of liquid are withdrawn from the bottom of the bubble-cap traycolumn and recycled into the extraction (2). A further 11 g/h of liquidare discharged from the bottom of the bubble-cap tray column anddiscarded.

The liquid withdrawn from the bottom of the bubble-cap tray column hasthe following composition:

-   -   0.003% by weight of 3-hydroxypropionic acid,    -   0.2% by weight of oligomeric 3-hydroxypropionic acid,    -   <0.0001% by weight of water,    -   0.2% by weight of acrylic acid,    -   0.6% by weight of oligomeric acrylic acid,    -   0.07% by weight of glycolic acid,    -   0.03% by weight of 2-hydroxypropionic acid,    -   <0.0001% by weight of formic acid,    -   <0.0001% by weight of acetic acid,    -   0.007% by weight of succinic acid,    -   0.02% by weight of fumaric acid,    -   <0.0001% by weight of formaldehyde,    -   <0.0001% by weight of acetaldehyde,    -   <0.0001% by weight of methanol,    -   <0.0001% by weight of ethanol and    -   0.07% by weight of pentamethyldiethylenetriamine,    -   2.0% by weight of diphyl and    -   96.8% by weight of dimethyl phthalate

Between the 15th and 16th trays of the bubble-cap tray column isinstalled a collecting tray. The liquid is withdrawn completelytherefrom and conveyed by means of a pump through a heat exchanger, inthe course of which it is cooled to 65° C., and is recycled to the 20thtray of the bubble-cap tray column. 750 g/h of the cooled liquid arewithdrawn as crude acrylic acid. 1379 g/h of the cooled liquid arerecycled to the 15th tray of the bubble-cap tray column.

The crude acrylic acid has the following composition:

-   -   <0.0001% by weight of 3-hydroxypropionic acid,    -   <0.0001% by weight of oligomeric 3-hydroxypropionic acid,    -   3.5% by weight of water,    -   96.4% by weight of acrylic acid,    -   <0.0001% by weight of oligomeric acrylic acid,    -   0.0075% by weight of glycolic acid,    -   <0.0001% by weight of 2-hydroxypropionic acid,    -   0.02% by weight of formic acid,    -   0.07% by weight of acetic acid,    -   <0.0001% by weight of succinic acid,    -   <0.0001% by weight of fumaric acid,    -   <0.0001% by weight of formaldehyde,    -   <0.0001% by weight of acetaldehyde,    -   0.0005% by weight of methanol,    -   0.002% by weight of ethanol and    -   <0.0001% by weight of pentamethyldiethylenetriamine,    -   <0.0001% by weight of diphyl and    -   <0.0001% by weight of dimethyl phthalate

Between the 25th and 26th trays of the bubble-cap tray column isinstalled a collecting tray. The liquid is withdrawn completelytherefrom and conveyed by means of a pump through a heat exchanger, inthe course of which it is cooled to 25° C., and is recycled to the 30thtray of the bubble-cap tray column. 213 g/h of the cooled liquid arerecycled into the extraction (2). 161 g/h of the cooled liquid arerecycled to the 25th tray of the bubble-cap tray column. The reflux isstabilized with 0.005% by weight of phenothiazine. The pressure at thetop of the bubble-cap tray column is 100 mbar.

The liquid withdrawn from the 25th tray of the bubble-cap tray columnhas the following composition:

-   -   <0.0001% by weight of 3-hydroxypropionic acid,    -   <0.0001% by weight of oligomeric 3-hydroxypropionic acid,    -   59.7% by weight of water,    -   40.0% by weight of acrylic acid,    -   <0.0001% by weight of oligomeric acrylic acid,    -   <0.0001% by weight of glycolic acid,    -   <0.0001% by weight of 2-hydroxypropionic acid,    -   0.14% by weight of formic acid,    -   0.15% by weight of acetic acid,    -   <0.0001% by weight of succinic acid,    -   <0.0001% by weight of fumaric acid,    -   0.002% by weight of formaldehyde,    -   0.001% by weight of acetaldehyde,    -   0.006% by weight of methanol,    -   0.001% by weight of ethanol and    -   <0.0001% by weight of pentamethyldiethylenetriamine,    -   <0.0001% by weight of diphyl and    -   <0.0001% by weight of dimethyl phthalate

The example shows that the acrylic acid prepared from renewable rawmaterials can be purified by the process according to the invention in asimple manner and with high yield.

1. A process for continuously dehydrating aqueous 3-hydroxypropionicacid to aqueous acrylic acid in a liquid phase, the liquid phase havinga temperature of 120 to 250° C., comprising continuously supplyingaqueous 3-hydroxypropionic acid to the liquid phase and continuouslywithdrawing the aqueous acrylic acid from the liquid phase, wherein theliquid phase comprises 5 to 95% by weight of an inert organic solvent 1.2. The process according to claim 1, wherein the liquid phase has atemperature of 130 to 220° C.
 3. The process according to claim 1,wherein the liquid phase comprises 30 to 60% by weight of the inertorganic solvent
 1. 4. The process according to claim 1, wherein theinert organic solvent 1 at a pressure of 1013 mbar has a boiling pointof 200 to 350° C.
 5. The process according to claim 1, wherein the inertorganic solvent 1 is selected from the group consisting of dimethylphthalate, diethyl phthalate, dimethyl isophthalate, diethylisophthalate, dimethyl terephthalate, diethyl terephthalate, nonanoicacid, decanoic acid, biphenyl, diphenyl ether, and mixtures thereof. 6.The process according to claim 1, wherein the dehydration is base- oracid-catalyzed.
 7. The process according to claim 1, wherein the aqueousacrylic acid is removed by distillation from the liquid phase.
 8. Theprocess according to claim 7, wherein distillation is effected with arectification column.
 9. The process according to claim 1, wherein aspace-time yield is from 10 to 150 kg/h of acrylic acid per m³ of liquidphase.
 10. The process according to claim 1, wherein a ratio ofoligomeric 3-hydroxypropionic acid to monomeric 3-hydroxypropionic acidin the aqueous 3-hydroxypropionic acid is at least 1:20 and/or the ratioof oligomeric 3-hydroxypropionic acid to monomeric 3-hydroxypropionicacid in the liquid phase is at least 1:1.
 11. The process according toclaim 1, wherein a residence time in the liquid phase is at least 10minutes.
 12. The process according to claim 1, wherein a polymerizationinhibitor 1 is added to the liquid phase.
 13. The process according toclaim 12, wherein the polymerization inhibitor 1 is selected fromphenothiazine, hydroquinone, hydroquinone monomethyl ether, or amixtures thereof.
 14. The process according to claim 1, wherein apolymerization inhibitor 2 is added to the aqueous acrylic acid.
 15. Theprocess according to claim 14, wherein the polymerization inhibitor 2 isphenothiazine, hydroquinone, hydroquinone monomethyl ether, or a mixturethereof.
 16. Aqueous acrylic acid obtained by a process according toclaim 1, the aqueous 3-hydroxypropionic acid having been prepared byfermentation.
 17. Aqueous acrylic acid comprising water and 20 to 80% byweight of acrylic acid, 0.001 to 1% by weight of formic acid, 0.001 to1% by weight of acetic acid, 0.001 to 1% by weight of glycolic acid,0.0001 to 0.05% by weight of formaldehyde, 0.0001 to 0.05% by weight ofacetaldehyde, 0.0001 to 0.05% by weight of methanol, 0.0001 to 0.05% byweight of ethanol and 0.0001 to 0.1% by weight of an inert organicsolvent
 1. 18. Aqueous acrylic acid according to claim 17, wherein theinert organic solvent 1 is selected from the group consisting ofdimethyl phthalate, diethyl phthalate, dimethyl isophthalate, diethylisophthalate, dimethyl terephthalate, diethyl terephthalate, nonanoicacid, decanoic acid, biphenyl, diphenyl ether, and mixtures thereof.